MANUAL 12 2 3 / 3 3 12 2 5 / 3 5 12 2 7 / 3 7 MultiMode™ MOTOR CONTROLLERS © 2000 CURTIS INSTRUMENTS, INC. DESIGN OF CURTIS PMC 1200 SERIES CONTROLLERS PROTECTED BY U.S. PATENT NO. 4626750. CURTIS PMC 235 East Airway Boulevard Livermore, California 94568 USA Tel: 925-961-1088 Fax: 925-961-1099 www.curtisinst.com 1223/33, 1225/35, 1227/37 Manual p/n 16879, Rev.
1223/33, 1225/35, 1227/37 Manual p/n 16879, Rev. B: September 2000 © 2000 CURTIS INSTRUMENTS, INC. This electronic version of the 1223/33, 1225/35, 1227/37 manual is offered as a convenience to our customers. You may download any or all of it. If you would like a hard copy of the published manual, please order it by part number from the Curtis office nearest you. The electronic version of the manual is identical to the printed version published in May 1996 (Rev.
CONTENTS CONTENTS 1. OVERVIEW ....................................................................... 1 2. INSTALLATION AND WIRING ..................................... 5 1223/33 Controllers ..................................................... 6 1225/35 Controllers ................................................... 10 1227/37 Controllers ................................................... 14 Throttle Wiring .........................................................
CONTENTS Direction Input Type ................................................. 34 Throttle Autocalibration ............................................ 35 Throttle Deadband .................................................... 36 Throttle Gain ............................................................. 37 Ramp Shape (Static Throttle Map) ............................ 38 Main Current Limit, M1/M2 .................................... 40 Emergency Reverse Current Limit .............................
FIGURES FIGURES FIG. 1: Curtis PMC 1221, 1225, and 1227 electronic motor controllers, with handheld 1307 programmer ................................................ 1 FIG. 2: Mounting dimensions, Curtis PMC 1223/33 controllers ......................................... 6 FIG. 3: Basic wiring configuration with on/off switches, 1223/33 controllers ............................................................. 8 FIG. 4: Basic wiring configuration with momentary switches, 1223/33 controllers ..........
FIGURES FIG. 17: Examples of speed curves with the speed limit pot in its maximum speed position ........................................ 30 FIG. 18: Examples of speed curves with the speed limit pot in its minimum speed position ........................................ 31 FIG. 19: Example of reverse speed curve ........................................ 32 FIG. 20: Effect of adjusting the neutral deadband parameter ......... 36 FIG. 21: Effect of adjusting the throttle gain parameter ..............
TABLES TABLES TABLE 1: Model comparison chart .................................................... 4 TABLE 2: Throttle styles .................................................................. 19 TABLE 3: Resistors for indicator LEDs ............................................ 26 TABLE 4: Programmable throttle input signal types ........................ 33 TABLE 5: Programmable direction input types ................................ 34 TABLE 6: Configuration options: Program 1 Driver ............
1 — OVERVIEW 1 OVERVIEW Curtis PMC 1223/33, 1225/35, and 1227/37 MultiMode™ controllers are programmable permanent magnet motor speed controllers designed for use in a variety of small electric vehicles. These controllers extend the capabilities of the 1208, 1203A, and 1213 families for applications where greater functionality or programmability is desired. The series includes Models 1223/33 (card only, 24–36V), Models 1225/35 (sealed case, 24–36V), and Models 1227/37 (ABS cover, 24–48V).
1 — OVERVIEW Like all Curtis PMC motor controllers, this family offers superior operator control of the vehicle’s motor drive speed.
1 — OVERVIEW ✓ Current limited brake driver protects the controller from shorts in the brake or its wiring; this low side output driver can also be programmed to enable a side broom or brush contactor, hour meter, etc.
1 — OVERVIEW Table 1 MODEL COMPARISON CHART MultiMode™ Microprocessor-Based Models Analog Models Voltage Range (V) Current Range (A) 1 Current Limited Regen.
2 — INSTALLATION & WIRING 2 INSTALLATION AND WIRING Installation and wiring instructions are presented separately for the 1223/33 controllers, 1225/35 controllers, and 1227/37 controllers. The three individual installation and wiring sections are followed by common sections that cover throttle wiring, auxiliary driver output options, and switches and other hardware. ☞ CAUTION Working on electric vehicles is potentially dangerous.
2 — INSTALLATION & WIRING: 1223/33 Controllers 1223/33 CONTROLLERS 1223/33 Installation The controller can be oriented in any position, but the location should be carefully chosen to keep the controller clean and dry. If a clean, dry mounting location cannot be found, a cover must be used to shield the controller from water and contaminants. The outline and mounting hole dimensions for the 1223/33 controllers are shown in Figure 2.
2 — INSTALLATION & WIRING: 1223/33 Controllers Although not usually necessary, a thermal joint compound can be used to improve heat conduction from the heatsink to the mounting surface. 1223/33 Low Current Connections A 16-pin low current connector provides the low current logic control connections. The mating connector is a 16-pin Molex Mini-Fit Jr. connector part number 39-01-2165 using type 5556 terminals.
2 — INSTALLATION & WIRING: 1223/33 Controllers 1223/33 Wiring Configurations The 1223/33 controller can be configured to work with either on/off or momentary switches for selecting direction and mode. If a power enable switch is used, it must be momentary style. For more information on control switches, see p. 24. With on/off switches Typical wiring for the 1223/33 controller with on/off switches is presented in Figure 3.
2 — INSTALLATION & WIRING: 1223/33 Controllers With momentary switches Typical wiring for the 1223/33 controller with momentary switches is presented in Figure 4. This diagram shows the controller configured with the program 1 driver as an electromagnetic brake, the program 2 driver as a brake light driver, and a single direction switch. NOTE: When a momentary switch is used for the mode input, the controller will always power up in Mode 1 (the default mode).
2 — INSTALLATION & WIRING: 1225/35 Controllers 1225/35 CONTROLLERS 1225/35 Installation The outline and mounting hole dimensions for the 1225/35 controllers are shown in Figure 5. Fig. 5 Mounting dimensions, Curtis PMC 1225/35 controllers. 148 (5.83) 4.57 (0.180) dia., 4 plcs 116 (4.58) 127 (5.0) 159 (6.25) 48 (1.88) Dimensions in millimeters and (inches) The 1225/35 controller can be oriented in any position.
2 — INSTALLATION & WIRING: 1225/35 Controllers 1225/35 Low Current Connections A 16-pin low current connector provides the low current logic control connections. The mating connector is a 16-pin Molex Mini-Fit Jr. connector part number 39-01-2165 using type 5556 terminals.
2 — INSTALLATION & WIRING: 1225/35 Controllers 1225/35 Wiring Configurations The 1225/35 controller can be configured to work with either on/off or momentary switches for selecting direction and mode. If a power enable switch is used, it must be momentary style. For more information on control switches, see p. 24. With on/off switches Typical wiring for the 1225/35 controller with on/off switches is presented in Figure 6.
2 — INSTALLATION & WIRING: 1225/35 Controllers With momentary switches Typical wiring for the 1225/35 controller with momentary switches is presented in Figure 7. This diagram shows the controller configured with the program 1 driver as an electromagnetic brake, the program 2 driver as a brake light driver, and a single direction switch. NOTE: When a momentary switch is used for the mode input, the controller will always power up in Mode 1 (the default mode).
2 — INSTALLATION & WIRING: 1227/37 Controllers 1227/37 CONTROLLERS 1227/37 Installation The 1227/37 controller can be mounted in any position, but the location should be carefully chosen to keep the controller clean and dry. If a clean, dry mounting location cannot be found, a cover must be used to shield the controller from water and contaminants. The outline and mounting hole dimensions for the 1227/37 controllers are shown in Figure 8.
2 — INSTALLATION & WIRING: 1227/37 Controllers 1227/37 Low Current Connections A 16-pin low current connector provides the low current logic control connections. The mating connector is a 16-pin Molex Mini-Fit Jr. connector part number 39-01-2165 using type 5556 terminals.
2 — INSTALLATION & WIRING: 1227/37 Controllers 1227/37 Wiring Configurations The 1227/37 controller can be configured to work with either on/off or momentary switches for selecting direction and mode. If a power enable switch is used, it must be momentary style. For more information on control switches, see p. 24. With on/off switches Typical wiring for the 1227/37 controller with on/off switches is presented in Figure 9.
2 — INSTALLATION & WIRING: 1227/37 Controllers the power enable function is performed by the keyswitch and a power enable switch is not used. With momentary switches Typical wiring for the 1227/37 controller with momentary switches is presented in Figure 10. This diagram shows the controller configured with the program 1 driver as an electromagnetic brake, the program 2 driver as a brake light driver, and a single direction switch.
2 — INSTALLATION & WIRING: Throttle THROTTLE WIRING The 1223/33, 1225/35, and 1227/37 controllers are programmable to suit a variety of throttles. If the throttle you are planning to use is not covered, contact the Curtis office nearest you. Mounting dimensions are provided in Appendix B for the standard 5kΩ, 3-wire throttle potentiometer (manufactured for Curtis PMC by Clarostat), the Curtis PMC potboxes and footpedals, and the electronic throttle ET-1XX (manufactured for Curtis by Hardellet).
2 — INSTALLATION & WIRING: Throttle Fig. 11 Wiring for 0–5V throttle. 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 + 4.7kΩ, 0.25W - B- PIN KEY required with wigwag throttles Pin 3 Pot Low Input Pin 2 0–5V Input Pin 1 Pot High Input Because the throttle input voltage is referenced to B- and no throttle connections are made to the pot high and pot low inputs, throttle fault protection is lost with 0–5V throttles.
2 — INSTALLATION & WIRING: Throttle Curtis ET-XXX Electronic Throttle The recommended wiring for the Curtis ET-XXX electronic throttle is shown in Figure 12. The ET-XXX throttle provides a single-ended 0–5V throttle signal and a signal indicating whether it is in forward or reverse. If the controller is configured to require only a single direction switch, only the reverse output wire (white wire) needs to be connected.
2 — INSTALLATION & WIRING: Throttle Speed Limit Pot A speed limit pot allows the operator to adjust the speed of the vehicle at full throttle. Wiring for the speed limit pot is shown in each of the basic wiring diagrams (Figures 3 & 4, 6 & 7, 9 & 10). The speed limit pot should be sized so that it does not affect the throttle input resistance and thus the throttle response. A 100kΩ pot is recommended.
2 — INSTALLATION & WIRING: Throttle The speed limit pot also limits the vehicle’s reverse speed. Reverse speed is linearly proportional to the speed limit pot setting and is adjustable from the Mode 1 minimum speed (speed limit pot in its minimum speed position) to the programmed maximum reverse speed (speed limit pot in its maximum speed position). If a speed limit pot is not used, the speed limit input (Pin 4) can be jumpered to the pot high input, as shown in Figure 14.
2 — INSTALLATION & WIRING: Auxiliary Drivers AUXILIARY DRIVER OUTPUT OPTIONS Program 1 The program 1 parameter configures a low side driver output at Pin 7. This output driver is typically programmed to drive an electromagnetic brake (as shown in the basic wiring diagrams (Figures 3 & 4, 6 & 7, 9 & 10). Alternatively, the program 1 driver can be programmed to drive an hour meter, sweeper/ scrubber brush motor contactor, brake light, etc. It is rated at 1 ampere and is protected from external shorts.
2 — INSTALLATION & WIRING: Switches, etc. SWITCHES AND OTHER HARDWARE Control Switches The control switches must be sized to handle a minimum 150 mA of current to the controller plus the current required for the indicator LEDs and any other accessories that they drive. The keyswitch must be an on/off switch. The power enable switch, if one is used, must be a momentary switch. The direction and mode selection inputs can be factory-configured for use with either on/off or momentary switches.
2 — INSTALLATION & WIRING: Switches, etc. Brake Release Switch (Brake Coil Disable Switch) If a brake release lever is used to release the electromagnetic brake mechanically, a brake coil disable switch is recommended. This switch opens the electromagnetic brake coil when the mechanical brake release lever releases the brake from the motor shaft. The open brake coil will register as a fault, inhibiting controller operation if an operator attempts to drive the vehicle with the brake mechanically released.
2 — INSTALLATION & WIRING: Switches, etc. If momentary switches are being used, the controller will drive the LEDs from an internal source. If on/off switches are used, the Direction LED and Mode Indicator LED are powered directly from the switches and only the Status LED is driven by the controller. If indicator LEDs are used, they should be installed with the proper resistors in series. The controller’s LED drivers are capable of providing a maximum current of 30 mA.
3 — PROGRAMMABLE PARAMETERS 3 PROGRAMMABLE PARAMETERS The 1223/33, 1225/35, and 1227/37 controllers have a number of parameters that can be programmed by means of a 1307 handheld programmer. These programmable parameters allow the vehicle’s performance characteristics to be customized to fit the needs of individual vehicle operators. Each controller is shipped with the parameter settings specified by the OEM.
3 — PROGRAMMABLE PARAMETERS The programmable parameters are described in the following order. They are listed in the text by the abbreviated names that appear in the programmer’s Program Menu. Not all of these parameters are displayed on all controllers; the list for any given controller depends on its specifications.
3 — PROGRAMMABLE PARAMETERS Acceleration/Deceleration Parameters M1 ACCEL RATE [default access: User] M2 ACCEL RATE [default access: User] The acceleration rate defines the time it takes the controller to accelerate from 0% output to 100% output. A larger value represents a longer acceleration time and a gentler start. Fast starts can be achieved by reducing the acceleration time, i.e., by adjusting the accel rate to a smaller value. The accel rate is adjustable from 0.2 seconds to 3.0 seconds.
3 — PROGRAMMABLE PARAMETERS Speed Parameters M1 MAX SPEED M2 MAX SPEED [default access: OEM] [default access: OEM] The maximum speed parameter defines the maximum controller output at full throttle with the speed limit pot in its maximum speed position. For example, if Mode 1 Maximum Speed is set at 60% and the speed limit pot is in its maximum speed position, the controller will provide 60% output at full throttle in Mode 1.
3 — PROGRAMMABLE PARAMETERS a speed limit pot is not used, the minimum speed parameter defines the maximum controller output at full throttle unless Pin 4 is jumpered to Pin 1 (see page 22). If the Pin 4–1 jumper is used, the maximum speed parameter defines the maximum controller output at full throttle and the minimum speed parameter is not applicable. In the examples shown in Figure 18, the minimum speed parameter is set at 50% in Mode 2 and at 20% in Mode 1.
3 — PROGRAMMABLE PARAMETERS Fig. 19 Example of 100 reverse speed curve with the speed limit pot in its maximum speed position. 90 PWM OUTPUT (percent) 80 70 60 50 REVERSE SPEED (set at 40%) 40 30 20 10 0 0 10 20 30 40 50 60 70 80 90 100 THROTTLE (percent) CREEP SPEED [default access: OEM] Creep speed helps to prevent vehicle rollback on inclines when the brake is released but low throttle is applied.
3 — PROGRAMMABLE PARAMETERS Throttle Parameters CAUTION ☞ It is strongly recommended that the throttle type and direction parameters be adjusted only when the controller is in a bench test setup. Changing these parameters while the controller is installed in the vehicle could result in vehicle runaway. If, for example, the throttle is a wigwag and the throttle type parameter is changed from wigwag to singleended, the vehicle will register a throttle input and begin to move without any operator control.
3 — PROGRAMMABLE PARAMETERS DIRECTION [default access: OEM] The direction input type defines how the controller decides when to change direction. For wigwag throttles, the direction input type defaults to respond to the throttle input. For single-ended throttles, this parameter can be set to either “single” or “dual.” The “single” setting allows the direction to be chosen via a single switch, which pulls the direction/reverse input (Pin 13) high when reverse is selected.
3 — PROGRAMMABLE PARAMETERS THRTL AUTOCAL [default access: OEM] The throttle autocalibration parameter provides a means of easily and reliably centering wigwag throttle pots. An audible tone and the Status LED assist the assembler in accurately centering the pot in the throttle assembly. The controller inhibits driving while in autocalibration mode, enabling the technician to adjust the throttle potentiometer safely. Throttle centering is accomplished as follows: 1.
3 — PROGRAMMABLE PARAMETERS THRTL DEADBAND [default access: OEM] The throttle deadband parameter defines the throttle pot wiper voltage range that the controller interprets as neutral. Increasing the throttle deadband setting increases the neutral range.
3 — PROGRAMMABLE PARAMETERS values shown in Figure 20 will hold true for any potentiometer value within the allowed 4.5 kΩ to 7.0 kΩ range. THRTL GAIN [default access: OEM] The throttle gain parameter sets the wiper voltage required to produce 100% controller output. Decreasing the throttle gain setting reduces the wiper voltage and therefore the full stroke necessary to produce full controller output. This feature allows reduced-range throttle assemblies to be accommodated.
3 — PROGRAMMABLE PARAMETERS throttle is used, the throttle gain parameter sets the pot wiper resistance required to produce 100% output in both forward and reverse: the wiper voltage required for full forward output is decreased, and the wiper voltage required for full reverse output is increased. NOTE: The throttle characteristics are defined in terms of wiper voltage rather than throttle pot resistance because of the range of pot values that can be used and the variation between pots of the same value.
3 — PROGRAMMABLE PARAMETERS Changing either the maximum speed setting or the creep speed setting changes the output range of the controller. Ramp shape output is always a percentage of the output range (the range between the creep speed and maximum speed settings). Ramp shapes with the creep speed setting raised from zero to 10% are shown in Figure 23. Fig. 23 Ramp shape 100 (throttle map) for controller with maximum speed set at 100% and creep speed set at 10%.
3 — PROGRAMMABLE PARAMETERS 35% PWM output at half throttle (halfway between 10% and 60%). The 30% ramp shape gives 25% PWM at half throttle (30% of the range {which is 50%, from 10% to 60%}, starting at 10% output, or {[.30 × 50%] + 10%} = 25%). Current Limit Parameters M1 MAIN C/L M2 MAIN C/L [default access: OEM] [default access: OEM] The main current limit parameter allows adjustment of the maximum current the controller will supply to the motor during both drive and regen operation.
3 — PROGRAMMABLE PARAMETERS Output Driver Parameters PROGRAM 1 [default access: OEM] The program 1 parameter configures an auxiliary low side driver (Pin 7). This output is rated at 1 amp and is short circuit protected. It can be programmed in any of seven configurations (Types 0–6 in the Program 1 Driver programming menu), as listed in Table 6. Any component can be controlled by this output provided its current requirements do not exceed the driver’s 1 amp rating.
3 — PROGRAMMABLE PARAMETERS PROGRAM 2 [default access: OEM] (123X models only) The program 2 parameter configures an auxiliary high side driver at Pin 16. This output is rated at 2 amps and is not short circuit protected. It can be programmed in any of eight configurations (Types 1–8 in the Program 2 Driver programming menu), as listed in Table 7. Any component can be controlled by this output provided its current requirements do not exceed the driver’s 2 amp rating.
3 — PROGRAMMABLE PARAMETERS PROGRAM 4 [default access: OEM] The brake holding voltage parameter allows selection of a voltage less than the full battery voltage to be applied to the brake coil when the brake is energized. This parameter is applicable only when the Program 1 driver is configured as an electromagnetic brake driver. The voltage is pulse width modulated and the setting represents the percentage of nominal battery voltage applied to the coil.
3 — PROGRAMMABLE PARAMETERS Other Parameters M1 IR COEFF M2 IR COEFF [default access: OEM] [default access: OEM] IR compensation is a method by which the controller maintains a constant vehicle speed despite changes in motor loading. The IR speed coefficient parameter adjusts how aggressively the controller tries to maintain constant speed under changing load conditions.
4 — OEM-SPECIFIED, FACTORY-SET PARAMETERS 4 OEM-SPECIFIED PARAMETERS (SET AT FACTORY) In addition to the programmable parameters described in Section 3, there are various parameters that can be set at the factory per the OEM’s specification. These parameters are not programmable with the 1307 programmer. If a change is desired, the controller must be returned to the factory for reconfiguration.
4 — OEM-SPECIFIED, FACTORY-SET PARAMETERS controller responds as if the speed limit pot is at its minimum speed position) until the wiper wiring is repaired. No error code is given, either in the Diagnostics Menu of the 1307 programmer or by the Status LED. However, this fault can be verified by selecting the Test Menu and observing the speed limit pot value as the pot position is changed.
4 — OEM-SPECIFIED, FACTORY-SET PARAMETERS “Drive,” the controller will limit the vehicle’s maximum speed to the specified emergency reverse speed regardless of mode or direction. This allows the vehicle to be moved out of the way or driven back to the maintenance area for repair. If configured as “disable,” the controller will inhibit all output to the motor until the emergency reverse wiring fault has been corrected.
4 — OEM-SPECIFIED, FACTORY-SET PARAMETERS KEY OFF DECEL The key off decel function decelerates the vehicle to zero speed per the specified deceleration delay if the keyswitch is turned off while the vehicle is in motion. If the key off decel function is disabled, the controller shorts the motor if the keyswitch is turned off, causing a severely abrupt stop of the vehicle. It is therefore recommended that the key off decel function be enabled.
5 — INSTALLATION CHECKOUT 5 INSTALLATION CHECKOUT Before operating the vehicle, carefully complete the following checkout procedure. If you find a problem during the checkout, refer to the diagnostics and troubleshooting section (Section 7) for further information. The installation checkout can be conducted with or without the handheld programmer. The checkout procedure is easier with a programmer. Otherwise, observe the LED for diagnostic codes. (The codes are listed in Section 7.
5 — INSTALLATION CHECKOUT throttle and motor. The motor should run proportionally faster with increasing throttle. If not, refer to Section 7. 5. If you are using a programmer, put it into the test mode by pressing the TEST key. Scroll down to observe the status of the switches: forward, reverse, inhibit, push enable, mode select, and emergency reverse (if applicable). Cycle each switch in turn, observing the programmer. The programmer should display the correct status for each switch.
5 — INSTALLATION CHECKOUT Fig. 25 Bench test setup for verifying and adjusting the controller’s parameters.
6 — PROGRAMMER OPERATION 6 PROGRAMMER OPERATION The universal 1307 Curtis PMC handheld programmer (optional) allows you to program, test, and diagnose Curtis PMC programmable controllers. The programmer is powered by the host controller, via a 4-pin connector located on the controller. When the programmer is first plugged into the controller, it displays the controller’s model number, date of manufacture, and software revision code.
6 — PROGRAMMER OPERATION The programmer is operated via an 8-key keypad. Three keys select operating modes (Program, Test, Diagnostics), two scroll the display up and down, and two change the values of selected parameters. The eighth key, the MORE INFO key, is used to display further information about selected items within any of the three standard modes.
6 — PROGRAMMER OPERATION CHANGE VALUE The two CHANGE VALUE arrow keys are used to increase or decrease the value of a selected menu item. Like the SCROLL DISPLAY arrow keys, the CHANGE VALUE arrow keys can be pressed repeatedly or be held down. The longer a key is held, the faster the parameter changes. This allows rapid changing of any parameter. An LED on each CHANGE VALUE arrow key indicates whether the key is active and whether change is permissible.
6 — PROGRAMMER OPERATION Some parameters on some controllers have dependencies on other parameters. This means that the available settings for one parameter may be dependent on the limits of another parameter. For example, your controller may not allow the reverse speed to be set below the Mode 1 minimum speed. In this example, if you attempt to reduce the reverse speed below the M1 minimum speed, a message will be displayed indicating that the minimum reverse speed is dependent on the M1 minimum speed.
6 — PROGRAMMER OPERATION To access the Special Program mode, first press the MORE INFO key. Then, while continuing to hold the MORE INFO key, press the PROGRAM key. The LED on the PROGRAM key will light, just as when the programmer is in Program mode. To distinguish between the Program and Special Program modes, look at the menu items in the display.
6 — PROGRAMMER OPERATION PEACE-OF-MIND PROGRAMMING Each time the programmer is connected to the controller, it acquires all the controller’s parameters and stores them in its temporary memory. You can revert back to these original settings at any time during a programming session via the Special Program Menu. Select “Reset All Settings” by scrolling it to the top of the display window, press the MORE INFO key, and follow the instructions displayed.
6 — PROGRAMMER OPERATION PROGRAMMER MENUS Items are listed for each menu in the order they appear in the actual menus displayed by the 1307 programmer.
6 — PROGRAMMER OPERATION Program Menu Notes (For more detail on these options, see Section 3: Programmable Parameters.
6 — PROGRAMMER OPERATION Test Menu (not all items available on all controllers) T HROT T L E S PD B A T T Throttle reading, in percent of full Speed limit percent: 0–100% Battery voltage across the capacitors Motor voltage Heatsink temperature Mode input: on/off Forward input: on/off Reverse input: on/off Inhibit input: on/off Main contactor: on/off Program 1 driver: on/off Program 2 driver: on/off Push enable input: on/off Emergency reverse input: on/off % L I M I T POT VO L T AGE MOTOR VO L T AGE
6 — PROGRAMMER OPERATION Diagnostics and Special Diagnostics “Menu” This is not a menu as such, but simply a list of the possible messages you may see displayed when the programmer is operating in either of the Diagnostics modes. The messages are listed in alphabetical order for easy reference.
7 — DIAGNOSTICS & TROUBLESHOOTING 7 DIAGNOSTICS AND TROUBLESHOOTING The 1223/33, 1225/35, and 1227/37 controllers provide diagnostics information to assist technicians in troubleshooting drive system problems. The diagnostics information can be obtained in two ways: observing the fault codes issued by the Status LED or reading the appropriate display on the handheld programmer. PROGRAMMER DIAGNOSTICS The programmer presents complete diagnostic information in plain language.
7 — DIAGNOSTICS & TROUBLESHOOTING Table 8 TROUBLESHOOTING CHART LED CODE PROGRAMMER LCD DISPLAY EXPLANATION POSSIBLE CAUSE HARDWARE F A I L SA F E 2 output fault 1. Short in motor or in motor wiring. 2. Controller failure. HARDWARE F A I L SA F E 4 overcurrent fault 1. Short in motor or in motor wiring. 2. Controller failure. HARDWARE F A I L SA F E 1 EEPROM fault 1. EEPROM failure or fault. HARDWARE F A I L SA F E 3 main contactor fault 1. Main contactor welded. 2.
7 — DIAGNOSTICS & TROUBLESHOOTING LED DIAGNOSTICS During normal operation, with no faults present, the Status LED is steadily on. If the controller detects a fault, the Status LED provides two types of information. First, it displays a slow flash (2 Hz) or a fast flash (4 Hz) to indicate the severity of the fault. Slow-flash faults are self-clearing; as soon as the fault is corrected, the vehicle will operate normally.
7 — DIAGNOSTICS & TROUBLESHOOTING Refer to the troubleshooting chart (Table 8) for suggestions about possible causes of the various faults. SPEED LIMIT POT FAULT The controller will not display a fault if there is a problem with the speed limit pot or its wiring. However, if the speed limit pot is broken or if any of its wires is open, the vehicle drive speed will be limited to the specified minimum speed in the selected mode.
8 — MAINTENANCE 8 MAINTENANCE There are no user serviceable parts in the Curtis PMC 1223/33, 1225/35, and 1227/37 controllers. No attempt should be made to open, repair, or otherwise modify the controller. Doing so may damage the controller and will void the warranty. However, it is recommended that the controller be kept clean and dry that its diagnostics history file be checked and cleared periodically. CLEANING 1223/33 Controllers The 1223/33 controllers do not have covers.
8 — MAINTENANCE diagnostic history file was cleared. The faults may be intermittent faults, faults caused by loose wires, or faults caused by operator errors. Faults such as contactor faults may be the result of loose wires; contactor wiring should be carefully checked out. Faults such as HPD or overtemperature may be caused by operator habits or by overloading. After a problem has been diagnosed and corrected, clearing the diagnostic history file is advisable.
APPENDIX A: GLOSSARY APPENDIX A GLOSSARY OF FEATURES AND FUNCTIONS Acceleration rate The acceleration rate is the time required for the controller to increase from 0 to 100% duty factor. The acceleration curve is controlled by the dynamic throttle response, which is linear. The acceleration rate is programmable—see Section 3, page 29. Access rights Each programmable parameter is assigned an access level—OEM or User—that defines who is allowed to change that parameter.
APPENDIX A: GLOSSARY Auxiliary driver: “Program 1” The program 1 driver is a short-circuit-protected low side driver capable of driving a 1 ampere load to B-. The program 1 driver is programmable and can be configured to drive an electromagnetic brake, hourmeter, brakelight, or sweeper/ scrubber brush motor contactor—see Section 3, page 41. Auxiliary driver: “Program 2” The program 2 driver is available only on 123X controllers (1233/1235/1237).
APPENDIX A: GLOSSARY Current limiting Curtis PMC controllers limit the motor current to a preset maximum. This feature protects the controller from damage that might result if the current were limited only by motor demand. PWM output to the power section is reduced until the motor current falls below the set limit level. In addition to protecting the controller, the current limit feature also protects the rest of the system.
APPENDIX A: GLOSSARY throttle is selected. However, repeatedly pressing the BB switch will reactivate the emergency reverse function each time. The emergency reverse speed and current limit are both programmable—see Section 3, page 32 (speed) and page 40 (current limit). ET-series electronic throttles The ET-XXX is a wigwag-style throttle control assembly, manufactured by Hardellet for Curtis. It provides a 0–5V signal in both the forward and reverse directions.
APPENDIX A: GLOSSARY Fault recording Fault events are recorded in the controller’s memory. Multiple occurrences of the same fault are recorded as one occurrence. The fault event list can be loaded into the programmer for readout. The Special Diagnostics mode provides access to the controller’s diagnostic history file—the entire fault event list created since the diagnostic history file was last cleared. The Diagnostics mode, on the other hand, provides information about only the currently active faults.
APPENDIX A: GLOSSARY HPD lockout (procedural/wiring fault) After 5 seconds of a continuous HPD fault, driving is inhibited until power to the controller is cycled. This feature prevents operation of a vehicle with a defective or misadjusted throttle. Inhibit The inhibit input is used to put the vehicle in a safe, non-drivable state during battery charging or under other conditions where this precaution is desired—see Section 2, page 25.
APPENDIX A: GLOSSARY LEDs The 1223/33, 1225/35, and 1227/37 controllers allow for the use of Light Emitting Diodes (LEDs) to show the condition of certain switches and to provide system fault information—see Section 2, page 25. Load compensation (see IR compensation) Missing brake detection If the electromagnetic brake coil circuit is open, the controller inhibits driving and shorts the motor.
APPENDIX A: GLOSSARY MultiMode™ The MultiMode™ feature of these controllers allows the vehicle to be operated with two distinct sets of characteristics. The two modes can be programmed to be suitable for operation under different conditions, such as slow precise indoor maneuvering in Mode 1 and faster, long distance, outdoor travel in Mode 2.
APPENDIX A: GLOSSARY commands are received. Normal operation resumes when the throttle is moved. If the throttle remains at neutral for 25 minutes, the controller powers down completely; normal operation resumes when the keyswitch (or power enable switch, if used) is cycled. Precharge The precharge feature soft-charges the controller’s internal capacitor bank when the controller is first turned on and before the main relay is engaged.
APPENDIX A: GLOSSARY netic brake mechanically released. The controller, even if it is powered off and there are no batteries in the system, will detect the motor voltage created by the moving vehicle. When this voltage becomes high enough, indicating that significant vehicle speed has been reached, the controller logic will power up and turn on the MOSFET power sections to short the motor and limit the speed of the vehicle.
APPENDIX A: GLOSSARY Smooth, stepless operation Like all Curtis PMC 1200 Series controllers, 1223/33, 1225/35, 1227/37 models allow superior operator control of the vehicle’s drive motor speed. The amount of current delivered to the motor is set by varying the “on” time (duty cycle) of the controller’s power MOSFET transistors. This technique—pulse width modulation (PWM)—permits silent, stepless operation. Speed interlocks The 1223/33, 1225/35, and 1227/37 controllers come standard with speed interlocks.
APPENDIX A: GLOSSARY current limit value as the controller’s power section heats up. Variations of up to 10% of the specified 1-minute current limit rating may be observed in applications where the controller undergoes significant heating. Attention to controller heatsinking will minimize this effect. Temperature data The temperature displayed in the 1307 programmer’s Test Menu is the instantaneous heatsink temperature at that moment, in degrees Celsius.
APPENDIX A: GLOSSARY Throttle fault protection 5kΩ, 3-wire potentiometer throttle For 5kΩ, 3-wire potentiometer throttles, the throttle fault detection circuitry meets ISO 7176 requirements. Also, throttle pot resistances outside the range of 4.5–7.5 kΩ are considered to be indicative of a faulty pot or faulty wiring, in which case the controller will register a pot fault. Fault detection causes the controller to decelerate to zero output.
APPENDIX A: GLOSSARY Throttle types The controller can be programmed to accept wigwag or single-ended signals from a 5kΩ, 3-wire pot or from a 0–5V voltage source—see Section 3, page 33. Undertemperature (see Thermal protection) Undervoltage protection Undervoltage protection automatically cuts back the controller output if battery voltage is detected below the undervoltage point at start-up, or when the battery voltage is pulled below the undervoltage point by an external load.
APPENDIX APPENDIXA: B: GLOSSARY THROTTLES APPENDIX B THROTTLE MOUNTING DIMENSIONS Fig. B-1 Mounting dimensions, Curtis PMC standard 5kΩ, 3-wire throttle potentiometer, p/n 98191. 14 (0.56) 20 (0.81) 28 (1.1) 6 (0.25) 35 (1.38) ELEC. SPECS: ELECTRICAL TRAVEL 40°± 3° TOTAL RESISTANCE (nominal) 5 kΩ HOPOFF RESISTANCE (max) 10 Ω Dimensions in millimeters and (inches) Fig. B-2 Mounting dimensions, Curtis PMC potboxes PB-5, -6, -9, and -10. 35 (1.38) 45° 42 (1.65) 10 (0.38) 60 (2.37) 32 (1.
APPENDIX B: THROTTLES APPENDIX A: GLOSSARY Fig. B-3 Curtis PMC footpedal FP-2. 112 (4.4) 1.8 m (6 ft) ≈15 ° 244 (9.6) GRN ON BLK 112 (4.4) WHT N.O. WIRING: GREEN / BLACK / WHITE = throttle input BLUE = switch, common ORANGE = switch, normally COM. BLU open ORG Dimensions in millimeters and (inches) Fig. B-4 Mounting 6 × 6 (0.24 × 0.24) dimensions, Curtis electronic throttle (ET series). VIS TC 3×12 ∅ M5 99 (3.90) 24 (0.94) 44 (1.73) 24 (0.94) 69 (2.72) 116 ° 22 (0.87) 44 (1.
APPENDIX APPENDIX C: SPECIFICATIONS A: GLOSSARY APPENDIX C SPECIFICATIONS Table C-1 SPECIFICATIONS: 1223/33 CONTROLLERS Nominal input voltage PWM operating frequency Electrical isolation to heatsink 24 V and 36 V 15 kHz 500 V ac (minimum) KSI input current (typical) Logic input current (typical) 100 mA without programmer; 150 mA with programmer 10 mA at 24 V Auxiliary Driver 1 current Auxiliary Driver 2 current Acceleration delay range Deceleration delay range 1 A (short circuit protected) 2 A (not sh
APPENDIX C: SPECIFICATIONS APPENDIX A: GLOSSARY Table C-2 SPECIFICATIONS: 1225/35 CONTROLLERS Nominal input voltage PWM operating frequency Electrical isolation to heatsink 24 V and 36 V 15 kHz 500 V ac (minimum) KSI input current (typical) Logic input current (typical) 100 mA without programmer; 150 mA with programmer 10 mA at 24 V Auxiliary Driver 1 current Auxiliary Driver 2 current Acceleration delay range Deceleration delay range 1 A (short circuit protected) 2 A (not short circuit protected) 0.
APPENDIX APPENDIX C: SPECIFICATIONS A: GLOSSARY Table C-3 SPECIFICATIONS: 1227/37 CONTROLLERS Nominal input voltage PWM operating frequency Electrical isolation to heatsink 24 V, 36 V, and 48 V 15 kHz 500 V ac (minimum) KSI input current (typical) Logic input current (typical) 100 mA without programmer; 150 mA with programmer 10 mA at 24 V Auxiliary Driver 1 current Auxiliary Driver 2 current Acceleration delay range Deceleration delay range 1 A (short circuit protected) 2 A (not short circuit protect
